Method and apparatus for securing non-ferrous objects

ABSTRACT

The present invention comprises methods and apparatuses for securing non-ferrous materials to ferrous objects and to each other using a combination of magnets and ferromagnetic materials.

BACKGROUND OF THE INVENTION

[0001] Without limiting the scope of the invention, the background is described in connection with the storage and organization of hand tools and other objects.

[0002] In the past, there have been various constructions combining molded, nonmetallic materials with magnets to provide a holder for metal objects. See, for example, U.S. Pat. No. 5,080,230. U.S. Pat. No. 3,405,377, issued to Pierce, discloses a construction that includes a series of parallel boards of nonmetallic material. U.S. Pat. No. 4,591,817, issued to Miller, discloses a socket holder that includes plate armatures that are laminated with magnetic material to define an assembly for holding sockets. U.S. Pat. No. 4,802,580, issued to Anderson, discloses a construction where parallel plates sandwich the magnetic material. To facilitate the alignment of items being retained, a third parallel plate is provided. U.S. Pat. No. 5,500,631, issued to Negus, discloses a magnetic holder that includes a molded plastic tray with a sinter bar having laminated keeper plates and magnetic bars positioned to define pole pieces that permit the forming of magnetic circuits.

[0003] U.S. Pat. No. 5,501,342, issued to Geibel, discloses a magnetic socket track that includes a base with concave grips the length of the outer sides. Two sections of ferrous metal with 90-degree bends lie inside the channel with the protrusions of the 90-degree bends facing each other. U.S. Pat. No. 4,802,580, issued to Andersen, discloses a pair of elongated, parallel and laterally spaced armature plates in which a plurality of magnets are mounted in positions spaced along the plates. The plates are constructed of ferrous material. The armature plates are assembled using a plurality of threaded fasteners that extend through the multiple plates and secure the armature plates.

[0004] The above-described patents disclose a number of devices having the same drawback. They are designed for use with ferrous or ferromagnetic materials such as regular steel. Many materials, however, are non-ferrous, including aluminum, magnesium, plastics, wood, sheetrock, and composite materials. Additionally, certain ferrous materials, such as a number of stainless steel alloys, are non-ferromagnetic. Due to emphasis on efficiency, weight savings, and corrosion resistance in modern product design, all of the above materials are seeing increased use in applications traditionally reserved for iron and steel. Accordingly, there is a need in the art for object securement methods and apparatuses suitable for use with non-ferrous materials and non-ferromagnetic steels.

SUMMARY OF THE INVENTION

[0005] The following summary of the invention is provided to facilitate an understanding of some of the innovative features unique to the present invention, and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

[0006] The present invention relates generally to the field of securement of objects, and in particular to a method and apparatus for securing non-ferrous objects to one another and to ferrous objects. In its various embodiments, the present invention includes a number of novel structures and assemblies to facilitate safe and efficient use of tools and other objects as well as improve the safety of workers using such devices.

[0007] In certain embodiments, the method of the present invention involves the introduction of ferrous or ferromagnetic material onto a non-ferrous surface, to facilitate securement of a magnetic holding device to the surface. In certain embodiments, the method of the present invention involves the introduction of ferrous or ferromagnetic material onto the surface of a non-ferrous object, to facilitate securement of the object to a magnetic holding device.

[0008] In one embodiment, the present invention includes a method of temporarily securing a ferrous object to a non-ferrous object comprising the steps of securing a first side of a ferrous sheet to the non-ferrous object, placing on the second side of the ferrous sheet a first side of a magnetic holder, said magnetic holder having a second side comprising a plate having an opening and a magnet having a first and a second magnetic region attached to the first plate and located on opposite sides of the at least one opening; and placing the ferrous object on the second side of the magnetic holder.

[0009] In another embodiment, the present invention includes a method of temporarily securing a non-ferrous object to a magnetic plate comprising the steps of securing a first side of a ferrous sheet to the non-ferrous object and placing the second side of the ferrous sheet on a side of a magnetic holder comprising a plate having an opening and a magnet having a first and a second magnetic region attached to the first plate and located on opposite sides of the at least one opening.

[0010] The novel features of the present invention will become apparent to those of skill in the art upon examination of the following detailed description of the invention or can be learned by practice of the present invention. It should be understood, however, that the detailed description of the invention and the specific examples presented, while indicating certain embodiments of the present invention, are provided for illustration purposes only because various changes and modifications within the spirit and scope of the invention will become apparent to those of skill in the art from the detailed description of the invention and claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.

[0012]FIG. 1 is an isometric view of one embodiment of the present invention showing the use of ferrous material to attach a magnetic holding device to a nonferrous, flat surface;

[0013]FIG. 2 is an isometric view of one embodiment of the present invention showing the use of ferrous material to attach a magnetic holding device to a nonferrous, curved surface;

[0014]FIG. 3 is an isometric view of one embodiment of the present invention showing a parts tray making use of ferrous material to attach a removable nonferrous parts bin to a magnetic holding device in the tray;

[0015]FIG. 4 is an isometric view of one embodiment of the present invention showing a vertical magnetic panel making use of ferrous material to secure nonferrous components to th e panel;

[0016]FIG. 5 an isometric view of one embodiment of the present invention showing a vertical magnetic display panel making use of ferrous material to secure non-ferrous components to the display panel;

[0017]FIG. 6 is a perspective view of one embodiment of a magnetic holding device useful with the methods and apparatuses of the present invention; and

[0018]FIG. 7 is a cross-sectional view along line 1-1′ of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

[0019] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.

[0020]FIG. 1 is an isometric view of an assembly 10 according to one embodiment of the present invention showing the use of a ferrous or ferromagnetic strip 14 to attach a magnetic holding device 18 to a non-ferrous, flat surface 12. In certain embodiments, strip 14 is composed of a polymer or elastomer binder loaded with ferromagnetic material. The binder can be any of a number of organic materials known to be compatible with the particular ferromagnetic material selected.

[0021] The ferromagnetic material can be any of a number of materials known to those of skill in the art as exhibiting ferromagnetic properties. Certain embodiments of the present invention use iron powder, while certain other embodiments use iron oxide powder. The ratio of ferromagnetic material to polymer binder may vary according to the strength of the magnetic bond. In certain embodiments, a ratio of 90% iron oxide powder to 10% polymer binder by weight has been found to be suitable. The thickness of strip 14 may vary according to the strength of magnetic securement required. It has been shown that the strength of magnetic securement increases with the thickness of strip 14.

[0022] Strip 14 may be attached to surface 12 by any of a number of methods known to those of skill in the art, including pressure-sensitive adhesive and mechanical fastening. In certain embodiments, strip 14 may be secured to surface 12 by a temporary adhesion method, such as by a temporary adhesive or by static electricity.

[0023] Magnetic holding device 18 is secured to strip 14 by a magnet 16 on the back surface of the magnetic holding device 18. Although magnet 16 is not attracted to non-ferrous surface 12, magnet 16 is attracted to ferrous strip 14 due to the ferromagnetic material embedded therein. In the embodiment shown in FIG. 1, magnetic holding device 18 incorporates a set of slots 20 in the front surface through which the magnetic field passes.

[0024] Once secured to surface 12 by ferrous strip 14 and magnet 16, magnetic holding device 18 can be used to secure ferromagnetic items such as wrench 22. It will be understood by one of skill in the art that wrench 22 is used only for purposes of illustration, and that any object capable of magnetic attraction can be secured using the above-described method.

[0025]FIG. 2 is an isometric view of an assembly 30 according to one embodiment of the present invention showing the use of a ferrous sheet 34 to secure a magnetic holding device 40 to a non-ferrous, curved surface 32. Curved surface 32 may be, for example, the aluminum skin of an aircraft or a composite body panel of an automobile. Ferrous sheet 34 is similar to ferrous strip 14 described in connection with FIG. 1, except that ferrous sheet 34 is necessarily flexible to some degree, whereas a rigid strip would work in the context of FIG. 1. Accordingly, the polymer or elastomer binder used to make ferrous sheet 34 must exhibit some degree of flexibility in order to conform to the contour of curved surface 32.

[0026] In the embodiment shown in FIG. 2, ferrous sheet 34 may be secured to curved surface 32 by any of the methods described above in connection with magnetic strip 14 of FIG. 1. In addition, ferrous sheet 34 is secured to curved surface 32 by straps 36 designed to hold ferrous sheet 34 in place on curved surface 32. Depending on the application, straps 36 may be the only method of securement employed, or may be used in combination with other methods of securement.

[0027] After securement of ferrous sheet 34 to curved surface 32 by straps 36 or other means, magnetic holding device 40 is secured to ferrous sheet 34 by magnet 38 on the back side of magnetic holding device 40. With magnetic holding device 40 mounted securely in place by magnetic attraction between magnet 38 and ferrous sheet 34, magnetic holding device 40 can be used to secure tools and other objects (not shown) for convenience or ornamentation.

[0028]FIG. 3 is an isometric view of one embodiment of the present invention showing a parts tray 50 making use of ferrous material 60 to attach a removable non-ferrous parts bin 58 to a magnetic holding device in the tray 50. As seen in FIG. 3, parts tray 50 comprises a tray frame 52 having a magnetic holding panel 54 disposed in the bottom thereof. In the embodiment shown in FIG. 3, magnetic holding panel 54 has a series of slots 56 in the top surface thereof, through which the magnetic field passes.

[0029] In the embodiment shown in FIG. 3, magnetic holding panel 54 securely holds parts bins 58 within parts tray 50, so that parts tray 50 can be moved around without concern that parts bins 58 will be dislodged. In certain embodiments, either or both of parts bins 58 and parts tray 50 may have a hinged lid thereon, for more reliable securement. Parts tray 50 may in certain embodiments incorporate one or more handles on one or more sides. It will be understood by those of skill in the art that, although this structure has been described in connection with parts storage, tray 50 would be equally suitable for storage of small tools or other small objects.

[0030]FIG. 4 is an isometric view of an assembly 70 according to one embodiment of the present invention showing a vertically-disposed magnetic panel 72 making use of ferrous material to secure non-ferrous components to the panel. As seen in FIG. 4, magnetic panel 72 has an array of slots 74 disposed therein for the transmission of magnetic fields to the surface. Magnetic panel 72 can be used for the securement of a wide variety of objects, including tools such as wrench 76, containers such as box 78, and/or other objects such as shelf 82 for holding objects such as sockets 86.

[0031] As seen in FIG. 4, box 78 has a ferrous pad 80 secured to the backside thereof, to allow it to be secured using magnetic panel 72. Similarly, shelf 82 has a ferrous strip 84 disposed on the backside thereof for the same reason. With ferrous pads 80 and ferrous strips 84 attached to the backside of boxes 78 and shelf 82, these objects are attracted to the magnetic field of magnetic panel 72 in the same manner as if they were made of ferrous material.

[0032]FIG. 5 an isometric view of one embodiment of the present invention showing a vertical magnetic display panel 90 making use of ferrous material to secure non-ferrous components to the magnetic display panel 90. Magnetic display panel 90 comprises a magnetic panel 92 having a cover sheet 94 disposed thereon to provide a uniform appearance. Cover sheet 94 may be a thin polymer or paper sheet and may in certain embodiments have a pattern disposed thereon.

[0033] Magnetic display panel 90 is suitable for creating any number of readily-assembled and readily-modified displays. Owing to the strong magnetic field produced by magnetic display panel 90, a variety of objects can be secured to magnetic display panel 90, including signs 96 and product packages 98.

[0034]FIG. 6 shows a perspective view of a magnetic holding device of the present invention, generally designated 100. The magnetic holding device 100 is depicted including a first and a second plate 102 and 104. Openings 106 are depicted that may form a channel within the first plate 102, while the second plate 14 does not have openings. The first and second plates 102, 104 are made of a magnetically conductive material, which can be a ferrous material or another material that contains sufficient magnetically conductive material to transfer or attain magnetic qualities.

[0035] Attachment points 107 may be provided and are depicted at four positions on first plate 102 and may be, for example, rivets, screws and like forms of attachment. The first and second plates may even be of unitary or single-plate construction, where one piece is folded in one or more ways to place the first and second plates generally parallel to each other.

[0036] When formed from one piece, the first plate 102 may be formed with the slots that form openings 106 while the second plate 104 may or may not have openings. Furthermore, it will be appreciated by those of skill in the art in light of the present disclosure that the openings 106 and the plates are not necessarily perpendicular or even generally rectangular. The openings 106 may be formed in a variety of shapes and widths depending on the type of object that will be placed in the magnetic holding device 100.

[0037]FIG. 7 is a cross-sectional view along line 1-1′ of FIG. 6 and depicts a magnets 108 a, 108 b and 108 c between the first plate 102 and the second plate 104. Each magnet 108 a, b, c, in one embodiment of the present invention, is a unipolar magnet in which a single pole of a magnetic field is formed perpendicular to the surface of the magnets 108 a, b or c. The magnetic field components of the unipolar magnet are generally perpendicular to the surface of the first and second plates 102, 104 and may be of about {fraction (1/16)}th to ¼th of an inch in thickness. As depicted in FIG. 7, the magnets 108 in each of the cases has a width that is less than the width of the portions of the first plate 102 that are over the magnets 108 a, b, c. Alternatively, the width of the magnets 108 a,b,c may be about equal to the width of the portion of plate 102 that is positioned over the magnets 108 a,b,c.

[0038] A lip 110 is defined by the region of the first plate 102 that extends over and past the magnets 108 a,b,c into the opening 106. The area within the opening 106 that is below the lip 110 and the magnets 108 a,b,c is a recessed region 112. As depicted in FIG. 7, the central magnet has recessed regions 112 on each side, while the end portions of the magnetic holding device 100 are not recessed.

[0039] The arrangement of the poles for the magnets 108 as depicted may be an N-S-N or an S-N-S configuration. It has been found particularly useful, however, to attempt to match the total width of a central region as depicted with the total width of the adjacent regions, whether in an N-S-N or an S-N-S polar configuration. If more magnets 18 are used adjacent to each other, or if a series of strips are used, whether linear, circular or of any other shape, the same principle may be applied, namely, that the total strength, not just width or size, of the polar regions are matched as best possible.

[0040] A wide variety of magnets may be used with the present invention such as rare earth magnets, ceramic magnets, alnico magnets, permanent magnets and flexible magnets. Flexible magnets are made by impregnating a flexible material such as neoprene rubber or a plastic with a material such as iron flakes having magnetic characteristics.

[0041] Examples of rare earth magnets include neodymium iron (NdFeB) and Samarium Cobalt (SmCo) classes of magnets. Within each of these classes are a number of different grades that have a wide range of properties and application requirements. Rare earth magnets are available in sintered as well as bonded form. The bonded form of the material can be produced with little or no finish. For use with the present invention, however, more finished materials will be preferred when using the tool holder of the present invention in the airline industry.

[0042] Ceramic magnets are sintered permanent magnets composed of Barium Ferrite (BaO (Fe2O3)n) or Strontium Ferrite (SnO (Fe2O3)n), where n is a variable quantity of ferrite. Also known as anisotropic hexaferrites, this class of magnets is useful due to its good resistance to demagnetization and its low cost. While ceramic magnets tend to be hard and brittle, requiring special machining techniques, these magnets can be used in tool holders having very precise specifications. Anisotropic grades are oriented during manufacturing, and must be magnetized in a specified direction.

[0043] Ceramic magnets can also be isotropic, and are often more convenient due to their lower cost. Ceramic magnets are useful in a wide range of applications and can be pre-capped or formed for use with the present invention. Ceramic magnets are very corrosion resistant, however, they do require some form of coating for use in the airline industry due to the formation of powder-like material. Therefore, a coating for the ceramic magnets is suggested to eliminate sloughing and chipping of the magnet.

[0044] Flexible magnets are magnets made of materials that are flexible and coated with a magnetic material. Flexible magnets offer the product designer a uniquely desirable combination of properties at a low cost. The advantage of materials that are flexible and coated with a magnetic compound is that they can be bent, twisted, coiled die punched, and otherwise machined into almost any shape without loss of the magnetic field. Under normal working conditions, flexible magnets are desirable due to their lack of a need for coating, are corrosion resistant, are easily machined, are easily handled, and can be coated with magnetic material having a high magnetic energy.

[0045] More expensive magnetic material, such as rare earth metal magnets, can be coated onto a flexible backing material, such as plastic, nylon or polypropylene, and will provide excellent magnetic strength and flexibility. In addition, the flexible magnets can be made very thin, e.g., with thicknesses of {fraction (1/18)}th of an inch or less.

[0046] Flexible magnets may also be attached to the tool holder of the present invention using adhesives that are suitable for a wide range of environments. The type of adhesive used to attach the flexible magnet will depend on the particular application, for example, the adhesive can be pressure sensitive. Laminate adhesive materials can be used to form laminate-type magnets. In addition, a plurality of adhesives can be used with the present invention.

[0047] Alnico magnets are composed primarily of alloys of aluminum, nickel and cobalt and are characterized by excellent temperature stability, high residual inductions, and relatively high energies. Alnico magnets are manufactured through either a casting or sintering process. Cast magnets can be manufactured to very high specifications and can have very specific shapes. Sintered alnico magnets offer slightly lower magnetic properties but better mechanical characteristics than cast magnets.

[0048] Alnico magnets are very corrosion resistant and are generally plated for cosmetic reasons. Coating may be particularly useful for cast alnico magnets because they are hard, brittle and prone to chipping and cracking. One disadvantage of alnico magnets is that they are easily demagnetized, however, this problem can be overcome with simple handling instructions. One advantage of alnico magnets is the smaller effect that temperature has on magnetic properties.

[0049] The embodiments and examples set forth herein are presented to best explain the present invention and its practical application and to thereby enable those skilled in the art to make and utilize the invention. Those skilled in the art, however, will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. Other variations and modifications of the present invention will be apparent to those of skill in the art, and it is the intent of the appended claims that such variations and modifications be covered. The description as set forth is not intended to be exhaustive or to limit the scope of the invention. Many modifications and variations are possible in light of the above teaching without departing from the spirit and scope of the following claims. It is contemplated that the use of the present invention can involve components having different characteristics. It is intended that the scope of the present invention be defined by the claims appended hereto, giving full cognizance to equivalents in all respects. 

What is claimed is:
 1. A method of temporarily securing a ferrous object to a non-ferrous object comprising the steps of: securing a first side of a ferrous sheet to the non-ferrous object; placing on the second side of the ferrous sheet a first side of a magnetic holder, said magnetic holder having a second side comprising a plate having an opening and a magnet having a first and a second magnetic region attached to the first plate and located on opposite sides of the at least one opening; and placing the ferrous object on the second side of the magnetic holder.
 2. The method of claim 1 wherein the ferrous sheet is secured to the non-ferrous object using pressure-sensitive adhesive.
 3. The method of claim 1 wherein the ferrous sheet is secured to the non-ferrous object using static electricity.
 4. The method of claim 1 wherein wherein the ferrous sheet is secured to the non-ferrous object using one or more straps.
 5. The method of claim 1 wherein the non-ferrous object is aluminum.
 6. The method of claim 1 wherein the non-ferrous object is a composite material.
 7. The method of claim 1 wherein the ferrous sheet is an iron-loaded polymer.
 8. The method of claim 1 wherein the ferrous sheet is an iron-loaded elastomer.
 9. The method of claim 1 wherein the ferrous sheet is an iron-loaded foam.
 10. A method of temporarily securing a non-ferrous object to a magnetic plate comprising the steps of: securing a first side of a ferrous sheet to the non-ferrous object; placing the second side of the ferrous sheet on a side of a magnetic holder comprising a plate having an opening and a magnet having a first and a second magnetic region attached to the first plate and located on opposite sides of the at least one opening.
 11. The method of claim 1 wherein the ferrous sheet is secured to the non-ferrous object using pressure-sensitive adhesive.
 12. The method of claim 1 wherein the ferrous sheet is secured to the non-ferrous object using epoxy.
 13. The method of claim 1 wherein wherein the ferrous sheet is secured to the non-ferrous object using one or more fasteners.
 14. The method of claim 1 wherein the non-ferrous object is aluminum.
 15. The method of claim 1 wherein the non-ferrous object is plastic.
 16. The method of claim 1 wherein the ferrous sheet is an iron-loaded polymer.
 17. The method of claim 1 wherein the ferrous sheet is an iron-loaded elastomer.
 18. The method of claim 1 wherein the ferrous sheet is an iron-loaded foam. 